Flame retardant-containing plastic shipping container

ABSTRACT

A halogen free fire resistant RF transparent polymer pallet has attenuated electrical resistance. A pallet body has a fire resistant layer and a substrate supporting the fire resistant layer. The fire resistant layer includes fire retardant materials, such as Al(OH) 3 , Mg(OH) 2 , intercalated graphite, zinc borate, and antimony oxide. The substrate is substantially free of the fire retardant materials to reduce the density and the electrical resistance of the pallet body. The fire resistant layer is substantially thinner than the substrate to lower RF distortion effects on RF transponder communications from additives and the conductive materials within an RF tracking system.

This application is a continuation of U.S. patent application Ser. No.11/894,288 filed on Aug. 20, 2007 which claims benefit of U.S. patentapplication Ser. No. 10/798,932 filed on Mar. 11, 2004, which claims thebenefit of U.S. patent application Ser. No. 09/803,681 filed on Mar. 12,2001, now U.S. Pat. No. 6,718,888 issued on Apr. 13, 2004. U.S. patentapplication Ser. No. 09/803,681 claims the benefit of U.S. ProvisionalApplication No. 60/196,127 filed on Apr. 11, 2000. This application isalso a continuation in part of U.S. patent application Ser. No.11/498,118 filed on Aug. 1, 2006, which is a continuation of U.S. patentapplication Ser. No. 10/771,916 filed on Feb. 4, 2004 and published onAug. 4, 2005 as U.S. Patent Publication No. 2005/171254, which was filedon even date with U.S. patent application Ser. No. 10/771,972 publishedas U.S. Patent Publication No. 2005/0170238.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a halogen free polyolefin materialcomposition, and in particular to a non-halogenated fire resistantplastic pallet that produces a reduced health risk to fire fightersduring fires, poses less environmental stress when made and used, offersgreater RF transparency for use of electronic devices, allows a lowerusage of comparably expensive fire retardant additives, yields a lowerweight structure for transport fuel savings and ergonomic handling andis 100% recyclable.

2. Description of Related Art

The wooden pallet is an integral part of North America's distributionsystem. Wooden pallets are involved in the movement of a significantproportion of all goods bought and sold. The U.S. Forest Serviceestimated that there were 1.9 billion wooden pallets in America in 1999.Approximately 400 million new pallets are needed each year. One hundredseventy five million of these are pallets repaired for reuse byindustry. Therefore, roughly 225 million new wooden pallets enter thesupply chain each year.

The Grocery Manufacturers of America (GMA), the largest end-user oftraditional 48 inch by 40 inch wooden pallets, have set forth thefollowing specifications for GMA style pallets: (1) exact48-inch×40-inch dimensions. Square in each direction; (2) true four-wayentry that is capable of accommodating existing pallet jacks from allfour sides (as opposed to current style with cutouts and stringers); (3)minimum-width pallet jack openings of 12 inches and minimum height of 3¾inch clearance when under load with the width of each center supportbeing less than six inches to accommodate pallet jacks; (4) smooth,non-skid, top-bearing surface should have at least 85% coverage (with100% being preferred) and the non-skid surface should be flat with noindentations or protrusions that could cause product damage; (5)bottom-bearing surface of no less than 60% coverage with properly placedcut-outs (12-inches square) for pallet jack wheels from four sides withthe surface being flat or having no indentations or protrusions thatcould cause product damage; (6) all bottom entry edges should bechamfered to ¼-inch for easy entry and exit; (7) overall height ofplatform should not exceed six inches; (8) rackable from both the48-inch and 40-inch dimensions with an allowable deflection in drive-inand drive through racks of no more than inch; (9) compatible with palletconveyors, pallet dispensers, skate-wheel pallet-flow racks, andautomatic storage and retrieval systems; (10) no protruding fasteners;(11) must be made of material that does not contaminate the product thatit carries; (12) must meet or exceed current pallet resistance to fire;(13) must be recyclable (preferably made of recycled material); (14)desired weight under 50 pounds; (15) load capacities of 2,800 pounds andcapable of bearing 2,800-pound loads safely in stacks five loads high;(16) repairs should be economically feasible; (17) weather resistant;(18) moisture resistant; and (19) capable of safely moving product,damage free, through the entire distribution channel with multiplecycles (from manufacturer through distributor to retail).

Recently, plastic materials have replaced wood with polyolefins, such aspolyethylene and polypropylene, as the primary plastic materials thatare used to construct plastic pallets. Polyethylene and polypropyleneare among the most widely used plastic materials. Polyethylene andpolypropylene provide excellent chemical resistance, easymanufacturability, strength, toughness and durability.

High density polyethylene (HDPE) and ultra high molecular weightpolyethylene (UHMWPE) are the preferred materials within thethermoforming sector of the plastics processing industry because oftheir relative ease of processiblity compared to polypropylene.Polyethylene grades exhibit heat deflection temperatures between 170° F.and 203° F. Polypropylene is more often a preferred material within theinjection molding sector of the plastics processing industry because ofits relative ease of processibility in this molding art. Polypropyleneis also the preferred material for structural foam molded pallets.

Pallets used in the grocery industry supply chain, for example,including wood pallets, must be 48×40 inches and able to support heavyloads (up to 2,800 pounds) when placed upon warehouse racks withcommodities stored thereon. When elevated temperatures exist within thewarehouse, the heavy load of the commodity can cause the polyethyleneand polypropylene pallets to deflect due to the fact that ordinarywarehouse racks only support pallets at their edges. Polyethylenebecomes rubbery at temperatures exceeding 120° F. and loses itsstrength. Polypropylene provides greater stiffness and retains itsstrength at temperatures up to 150° F. Polyethylene and polypropyleneare also the lowest cost commodity grade resins available on the market.

One approach to overcoming heat deflection problems is to addthermosetting resins to the polyolefin base material to provide increasestiffness and load strength. U.S. Patent Application Publication Nos.2003/0108700 and 2004/0059035 disclose a plastic shipping or storagecontainer having a friction material on the outer surface. The containeris formed from a material that has a thermosetting component, apolyolefin component, and a friction layer component. The friction layercomponent provides the protected surface of the container with a staticcoefficient of friction of dry or wet surfaces in the range of 0.60 to1.20, preferably in the range of 0.75 to 1.00, and more preferably inthe range of 0.80 to 1.00. For oily surfaces, a desirable containercoefficient of friction is in the range of 0.30 to 1.00, preferably inthe range of 0.40 to 1.00, and more preferably in the range 0.50 to0.95. In some embodiments of the invention the container is providedwith different coefficients of friction in different locations on thecontainer. The thermosetting component requires a catalyst for curing toform a semi-interpenetrating network.

Most traditional polyolefin resins that include thermosetting componentscannot be processed using conventional thermoforming and injectionmolding techniques. The equipment required to process resins thatinclude thermosetting components, such as the resins disclosed in U.S.Patent Application Publication Nos. 2003/0108700 and 2004/0059035, isnot the same as those organized for purely thermoplastic resins. Resinsthat include thermosetting components can be processed by resin transfermolding, sheet molding compounding, and other similar moldingtechnologies.

Another problem with adding thermosetting resins to a thermoplasticpallet material is that thermosetting resins add weight to the finishedproduct. The additional weight increases transportation costs throughincreased fuel costs. The additional weight also increases the potentialfor injury by decreasing the ergonomics of the pallet. Thermosettingresins are also not readily recycled.

Another approach to overcoming heat deflection problems is to add fibersor fillers to the base material to add strength. U.S. Pat. No. 5,143,778discloses a polyethylene structural material that is reinforced withtalc fillers. Fibers and filler can replace rigid cross members.

Another problem with plastic pallets is fire resistance. While wood isinherently combustible and easily ignited, the National Fire ProtectionAssociation (of America)(NFPA) has raised concerns about thefire-related risks of plastic pallets. The NFPA promulgated NFPA 231code standards governing sprinkler systems that suppress fires inwarehouses involving wood pallets. The NFPA 231 code standards reducedthe severity of fires involving wooden pallets as the source of risk.

The National Association of Fire Marshals, the NFPA, the insuranceindustry, pallet users, and other members of the fire community havedetermined that NFPA 231 fire suppression systems are inadequate tosuppress the increased heat and combustibility of plastic pallet fires.The fire community replaced NFPA 231 with NFPA 13 in 1999 to distinguishthe fire risk of wood and plastic pallets.

The NFPA 13 change allows plastic pallets to be treated like woodenpallets if test data indicates that the burning characteristics of thetested plastic pallets are equal to or better than wood. TheUnderwriters Laboratory (UL) 2335 and Factory Mutual (FM) 4995 testprotocols were subsequently developed to classify plastic pallets thatmeet NFPA 13. UL 94 5VA is the highest (most flame retardant) UL 94rating system. A 5VA rating does not insure compliance with UL 2335.Polyethylene and polypropylene overwhelmingly represented the highestportion of the preferred materials for the manufacture of plasticpallets at the time of the NFPA 13 change.

NFPA 13 also places other restrictions on wood pallets and plasticpallets that comply with UL 2335 and FM 4995 standards. For example, itis a code requirement that empty pallets that are stacked together (in“idle storage”) are stored outside the warehouse in order to reduce thefire risk posed by both wood and plastic pallets during idle storage ifthe sprinkler systems have not been upgraded to particular NFPAstandards. These additional code restrictions reduce the over-allefficiency of a smooth flowing distribution operation and add furtherhandling and storage costs. The problem of retrieving pallets fromoutside in winter with snow on the ground using a fork-lift is a case inpoint. If a much reduced fire risk pallet was used, the NFPA standardscould be modified to allow for the idle storage of low fire risk plasticpallets that have a “lower” rather than “equal” risk with wood to bekept in idle storage inside a warehouse. A low risk plastic pallet istherefore needed to improve the supply chain.

Another small-scale test is set forth in ASTM E1354. The ASTM E1354 testis used by the fire community to pre-test a raw material. Thisbench-scale test is performed before a potential pallet is submitted forfull-scale testing as a pallet according to UL 2335 or FM 4995 testmethods. Ordinary polyethylene and polypropylene that are testedaccording to ASTM E1354 have significantly higher average peak heatrelease rates than wood. Therefore, the commercial viability of ordinarypolyethylene and polypropylene pallets was greatly reduced with the NFPA13 change.

One approach to reduce the fire related risks associated with polyolefinpallets is to replace the polyolefin materials with other plastics. U.S.Pat. No. 6,784,234 discloses a high performance plastic pallet thatutilizes resin compositions that include polyphenylene ether (PPE)homopolymers or copolymers. The PPE resins perform as well or betterthan wood in UL 2335 testing, typically having an average peak heatrelease rate of +/−550 kW/m² with a heat flux of 35 kW/m². The disclosedPPE resins are highly engineered resins that typically cost more thanfour times the cost of ordinary polyethylene and polypropylene. The PPEresins are also heavier than ordinary polyethylene or polypropylene.Consequently, PPE resins have not been widely used to make palletsbecause of expense and weight considerations.

U.S. Patent Application Publication No. 2005/0004281 discloses a highperformance plastic pallet. The pallet is manufactured frompolyphenylene ether resin, polycarbonate resin, vinyl aromatic graftcopolymer resin, polyetherimide resin, or thermosetting resins. Thepallet has an open deck design. The pallet is also designed to pass theUL 2335 protocol.

Another approach is to add fire retardants to the polyolefin basematerial. These additives may be incorporated into an outer coating orinto the base material. U.S. Pat. No. 6,758,148 discloses a palletassembly having at least one pallet member having external surfaces anda flame retardant material affixed to at least one pallet member so asto substantially cover all of the external surfaces of the palletmember. The fire retardant material includes poly-tetrafluoroethylene(PTFE) or teflon.

The introduction of fire retardant additives reduces the processibilityof the plastic material having fibers and fillers while adding extraprocurement and implementation costs. U.S. Pat. No. 6,998,433 disclosesa pallet having up to 30 wt % magnesium hydroxide, 8 wt % aluminatrihydrate, 8 wt % zinc borate, and 54 wt % polyolefin resin. Thepreferred embodiment has 38 wt % of fire retardants. Highly loadedmaterials (i.e. materials loaded in excess of 45%) have reducedprocessibility of the base material.

Also, highly loaded materials have a reduced capacity for reinforcingfibers and fillers, which must be replaced by rigid cross members toprovide elevated temperature load strength. Rigid cross members add costand weight to the finished product.

Several halogenated fire retardant packages that a practitioner canblend into a polyethylene or polypropylene resin are commerciallyavailable. For example, Faralloy® PE-106 is an extrusion grade, UVresistant, non-blooming flame retardant HDPE supplied by O'Neil Colorand Compounding of Garfield, N.J.

Fire resistant additives for polyethylene and polypropylene may alsoinclude halogenated organic brominates, chlorinates, phosphates andphosphorus flame retardants. These additives can be used to constructfire resistant pallets having an average peak heat release rate of lessthan 600 kW/m² at a heat flux of 35 kW/m³, according to ASTM E 1354.Halogenated materials, however, are known to be dangerous to firefighters and the environment because they release hazardous gases duringfire.

U.S. Pat. No. 6,807,910 discloses a pallet assembly that include halogenbased flame retardant resin additives that are added to the polyolefinmaterials like polyethylene and polypropylene to provide acceptableflame resistance. The plastic pallet can be fabricated from just onetype of material.

U.S. Pat. No. 6,955,128 discloses a pallet assembly that includeshalogen based flame retardant resin additives. The pallet assemblyincludes a series of triangular holes on the top surface and a series ofribs on the underside. The structure includes holes that provide apathway for flames to migrate through the pallet, which can ignitecombustible objects or commodities supported upon the pallet. Theexposed ribs also increase the surface area of exposure to fire andprovide more potential fuel for combustion.

U.S. Pat. No 6,849,677 discloses a pallet that uses a polyolefin moldingresin containing a flame retardant package containing a halogenatedorganic flame retardant, alumina trihydrate, and antimony trioxide. Theflame retardants are supplied as a master batch at a concentrationhigher than that desired in the pallet, in a polyolefin-compatiblepolymer. The flame retardant ingredients are incorporated into thepolyolefin by conventional techniques. The halogenated fire retardant istetra-bromobisphenol A (TBBA), a brominated flame retardant having theformula (CH₃)2C[C₆H₂(Br)₂OH]₂. TBBA and other halogenated precursors arealso widely used in the cable and wire industry where PE and PP jacketsare provided with fire retardant additives so that the cable and wirecasing will not ignite and allow a fire to migrate from room to room.

The disclosed inorganic metals and compounds identified are commerciallyavailable in master batch quantity from O'Neil Color and Compounding ofGarfield, N.J. The O'Neil Color & Compounding UL Yellow Card forFaralloy® PE-401, has the highest 94-5VA rating.

It is also widely known that antimony trioxide and zinc borate aresubstantially interchangeable inorganic compounds that act as synergistswith hydrated alumina and magnesium and promote lower smoke releaserates, as measured in ASTM E1354. Finally, zinc borate would bepreferred over antimony for its smoke density fighting proficiency andwhite smoke coloration.

U.S. Pat. Nos. 5,834,535 and 6,184,269 disclose moldable intumescentcompositions that provide a heat or fire barrier to a polyethylene orchlorinated polyethylene base material. An intumescent material is onethat undergoes a chemical change when exposed to heat and fire, formingexpanding bubbles that harden into a dense, heat insulatingmulti-cellular char. At the same time that the char is forming, metaloxides release water to wick the fire to provide a fire resistanteffect.

The disclosed moldable resin formulations include inorganic wateremitting substances (hydrated magnesium, alumina, and intercalatedgraphite), organic nitrogenous agents that release gases that inhibitcombustion (ureas, melamine, cyanurates, and carbonates), smokesuppressants (antimony trioxide and zinc borate), and strengtheningfillers (fibers and particles). The composition can be blow molded,injection molded, compression molded or otherwise suitably molded andshaped to a desired geometry or configuration by thermal processes. Asmall amount of hydrated carbon that is beneficial for the formation ofchar in a process of intumesence is also disclosed.

The disclosed compositions utilize an organic nitrogenous agent. Thesenitrogenous agents release gases that inhibit combustion. Nitrogenousagents include ureas, melamine, cyanurates, carbantes and the like. TheAbu-Isa formulations provide a two-stage fire suppression effect,whereas the Overholt formulations provide only a single stage firesuppression effect.

U.S. Pat. No. 6,706,793 discloses an intumescent polymer composition.The composition includes a halogenated polymer and an intumescentadditive. The intumescent additive includes antimony oxide andintercalated graphite.

U.S. Pat. No. 6,809,129 discloses a moldable elastomeric intumescentmaterial. The material includes chlorinated polyethylene, plasticizers,phosphate based foaming agents, char forming materials, antioxidants,intumescent materials, flame retardant materials, and graphite and/orexpandable graphite. The material may also include a curing agent or aco-curing agent.

The materials described therein contain halogenated materials, namely,chlorinated polyethylene, which may generate corrosive HX gases, such asHCl. These toxic by-products are dangerous to persons exposed thereto.Many similar efforts to develop flame retardant systems utilizehalogenated components because halogens are very efficient fireretardants. However, because they are environmentally unfriendly, it isdesirable to find a fire retardant system that does not use halogens.

U.S. Pat. No. 6,998,433 discloses flame retardant molded polyolefinpallets. The disclosed polyolefin material includes a flame retardantpackage that includes magnesium hydroxide, alumina trihydrate, and zincborate. Alumina trihydrate, and its functional hydrated aluminaequivalent Al(OH)₃, on heating to a critical temperature decomposes into66% alumina and 34% water. Alumina trihydrate (ATH) has a specificgravity of 2.42 g/cm³. (polyethylene and polypropylene have a specificgravity below one +/−0.95 g/cm³). The disclosed inorganic metals andcompounds identified are commercially available in master batch quantityfrom O'Neil Color and Compounding of Garfield, N.J.

U.S. Patent Application Publication No. 2006/0004134 also disclosesflame retardant molded polyolefin pallets. The disclosed polyolefinmaterial includes magnesium hydroxide as the primary fire retardantcomponent.

U.S. Pat. No. 6,228,914 discloses an aqueous intumescent compositionthat includes a melamine compound, an acidic phosphorous compound, andexpandable graphite flake. The graphite flake is present in an amount offrom 10 to 60 percent by weight. The disclosed compostion could not beemployed in the practice of the present invention because it has arelatively low “onset” intumescent temperature, which means that it willcommence exfoliation generally after only a few seconds of exposure toan elevated temperature.

U.S. Patent Application Publication No. 2004/0006164 discloses anintumescent fire retardant polymeric composition. The compositionincludes a thermoplastic polymer, an intumescent, and a fire-resistantadditive. The thermoplastic polymer has less than fifty weight percentof the total composition.

U.S. Pat. No. 5,984,126 discloses a non-metallic industrial container,such as a plastic drum, a fiber drum, composite intermediate bulkcontainer, or other suitable industrial container, having a fireresistant outer layer. The fire resistant outer layer is a thermoplasticpolymer filled with intumescent powder. The outer layer is co-extrudedonto the structure.

Therefore, a need for light weight, low cost polyethylene andpolypropylene pallets having high temperature load bearing strength andfire resistance exists. An additional need exists for a plastic palletthat poses a significantly lower fire risk than wooden pallets. Suchpallets provide a significantly lower fire risk than wood that is storedinside a warehouse or wood that is stored on ordinary warehouse racking.Such pallets also achieve lower insurance risk premiums.

Many of the patents and patent applications that are discussed in thissection have filing dates that occurred after one or more of thepriority dates for the patents and patent applications that areidentified in the previous section. Accordingly, the citation anddiscussion of a patent or patent application in this section should notbe construed as an admission that that patent or patent application is aprior art reference.

SUMMARY OF THE INVENTION

In accordance with the present invention there is provided a pallet. Athermoplastic pallet body has a fire retardant layer and a supportlayer. The fire retardant layer includes a polyolefin material and fireretardant fillers that provide an average peak heat release rate between300 kW/m² and 500 bkW/m² with a heat flux of 35 kW/m². The support layerhas a polyolefin material with an effective amount of low resistivityadditives imparting high temperature strength. An RF transponder havinga unique identifier for identifying the pallet within a network ispositioned within the pallet body. The pallet body has attenuatedresistance to RF signals. The fire retardant layer and the support layerare substantially halogen free.

Further in accordance with the present invention, there is provided aplastic pallet for use in an RF tracking system. A pallet body has anouter layer positioned on the exterior of the pallet body and an innerlayer for providing load support to the outer layer. The outer layer hasfire retardant additives that include conductive materials. The outerlayer is substantially thinner than the inner layer to lower RFdistortion effects on RF transponder communications from the fireretardant additives and the conductive materials within the RF trackingsystem.

Further in accordance with the present invention, there is provided ahalogen free fire resistant RF transparent polymer pallet havingattenuated electrical resistance. A pallet body has a fire resistantlayer and a substrate supporting the fire resistant layer. The fireresistant layer has fire retardant materials selected from the groupconsisting of Al(OH)₃, Mg(OH)intercalated graphite, zinc borate, andantimony oxide. The substrate is substantially free of the fireretardant materials to reduce the density and the electrical resistanceof the pallet body.

Further in accordance with the present invention, there is provided afire resistant polymer pallet structure having a resistive layer with anattenuated penetration depth. A surface layer has a low densitypolyethylene blend with a halogen free organic water emitting substance.A substrate layer has a high density polyethylene blend with a fillerselected from the group consisting of non-resistive strengtheningfibers, flakes and fillers.

Further in accordance with the present invention, there is provided apolymer pallet for attenuating resistivity. A pallet body has a firstlayer with fire retardant materials added therein and a second layerthat is substantially free of the fire retardant materials. The firstlayer is co-extruded with the second layer to form a uniform wall havingsufficient thickness to support a load. The wall propagates a magneticfield emanating from a source direction that is positioned adjacent tothe first layer to a transponder that is positioned in a directionadjacent to the second layer.

Accordingly, a principal object of the present invention is to provide aGMA style 40×48 inch rackable pallet that weighs 50 pounds or less.

Another object of the present invention is to provide a GMA style palletthat is skid resistant.

A further object of the present invention is to provide a GMA stylepallet that is not harmful to fire fighters attending a fire.

Another object of the present invention is to provide a GMA style palletthat is amenable to the use of RF tracking devices.

Another object of the present invention is to provide a GMA style palletthat can withstand the handling conditions operating in a materialhandling environment.

Another object of the present invention is to provide a GMA style palletthat is 100% recyclable.

A further object of the present invention is to provide a GMA stylepallet that is low in cost.

Another object of the present invention is to provide a GMA style palletthat comprises a deck and a base, and in particular a deck that providesup to 100 percent surface coverage.

A further object of the present invention is to provide a GMA stylepallet that comprises a deck and a base, and in particular a base thatprovides up to 60 percent surface coverage.

These and other objects of the present invention will be more completelydescribed and disclosed in the following specification, accompanyingdrawings, and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a conventional injection molded palletassembly.

FIG. 2 is an exploded isometric view of a deck for the conventionalinjection molded pallet assembly shown in FIG. 1.

FIG. 3 is an exploded isometric view of a GMA style plastic palletassembly.

FIG. 4 is an isometric view of a nine-legged plastic pallet assembly.

FIG. 5 is an exploded fragmentary cross sectional view in side elevationof two interlocking triple sheet thermoformed deck members.

FIG. 6 is a fragmentary cross sectional view in side elevation of atriple sheet thermoformed pallet assembly.

FIG. 7 is a cross sectional view in side elevation of a deck member thatis constructed out of a composite material.

FIG. 8 is a cross sectional view in side elevation of a deck memberhaving a twin layer wall.

FIG. 9 is a cross sectional view in side elevation of a deck memberhaving a triple layer wall.

FIG. 10 is a cross sectional view in side elevation of a deck memberhaving a triple layer wall with reinforcing flakes, fibers, or fillers.

FIG. 11 is a schematic diagram of a cross section of a single walledpallet member.

FIG. 12 is a schematic diagram of a cross section of a twin walledpallet member.

FIG. 13 is a schematic diagram of a cross section of a triple walledpallet member.

FIG. 14 is a schematic diagram of a cross section of a pallet memberhaving enclosed foamed structures.

FIG. 15 is a schematic diagram of a cross section of a pallet memberhaving separately molded reinforcing structures inserted therein.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The fire resistant apparatus of the present invention is employed withapparatus similar to that illustrated in U.S. Pat. No. 6,718,888, whichdiscloses a fire resistant pallet. The pallet includes a firstpolyolefin layer having intumescent materials and a co-extruded secondlayer. The pallet utilizes a moldable intumescent resin particularlysuitable for thermoforming applications and amenable to deep draw ratiosof 400%, which is disclosed in U.S. Pat. No. 5,834,535.

Samples of a plastic sheet that include a halogen free intumescentmaterial mixture that otherwise resembles the composition disclosed inU.S. Pat. No. 5,834,535 were laminated over a halogen free layer of highdensity polyethylene material. The mixture simulated an externallyfacing co-extruded plastic wall. The samples were tested according toASTM E1354 and found to have an average peak heat release rate of 203kW/m².

This high level of fire retardation is significantly more effective thanordinary fire resistant polyethylene materials. This material is alsomore effective than such high cost engineered materials that meet the UL2335 standard, such as Noryl® thermoplastic resins from General ElectricCompany of Selkirk, N.Y.

The fire resistant halogen free apparatus of the present invention isalso employed with apparatus similar to that illustrated in U.S. Pat.Nos. 6,943,678 and 7,097,900. The apparatus is also employed withapparatus similar to U.S. Patent Application Publication No.2005/0237184. Detailed descriptions of the disclosed methods andapparatus will not be discussed herein. The present invention will bedescribed as it relates to apparatus disclosed in the above enumeratedpatent and patent application. The above enumerated patents and patentapplication are also incorporated herein by reference.

Referring to the drawings and particularly to FIGS. 1-2, there isillustrated a conventional plastic pallet, generally designated by thenumeral 10. The pallet 10 is similar to the GMA style plastic palletdisclosed in U.S. Pat. No. 6,807,910. The pallet 10 is formed frominjection molded pallet members.

The pallet 10 includes a deck 12, a base 14, and a plurality of spacedapart columns 16, 18 positioned between the deck 12 and the base 14. Thecolumns 16, 18 include columns 16 positioned at the corner of the pallet10 and intermediately-positioned columns 18. The deck 12, the base 14,and the columns 16, 18 form a plurality of openings 20 for receivingforklift tines (not shown). A top surface 22 of the deck 12 includes aplurality of openings 24 that provide weight reduction by decreasing theamount of material that is used to form the pallet 10.

The pallet 10 does not include an effective double layered wall becausethe deck 12 includes less fire retardant materials than the base 14. Thepallet openings 24 also provide increased surface area and otherpathways for facilitating the spread of fire.

Referring now to FIG. 2, the deck 12 is formed from a top member 26 anda bottom member 28. The bottom member 28 includes column connectionsections 30 for receiving the columns 16, 18 from FIG. 1. Each member26, 28 and column 16, 18 is uniformly molded from a single type ofmaterial. Alternatively, the members 26, 28 and columns 16, 18 areconstructed from different materials, so that the combination of columns16, 18 and members 26, 28 includes multiple materials having differentfire retardant properties.

The top member 26 includes a plurality of holes 30. The bottom member 28also includes a plurality of holes 32. The holes 30, 32 join each otherwhen the top member 26 and the bottom member 28 are fused together, sothat the surrounding material forms box-like structures to provide arigid deck 12. The holes 30, 32 also reduce the volume of plastic in thedeck 12. Alternatively, the deck 12 includes only a top member (notshown) having column details (not shown) and egg-create structures withopenings (not shown).

Referring now to FIG. 3, a GMA style rackable pallet assembly inaccordance with the present invention and generally designated by thenumeral 36 is shown. The pallet assembly 36 has a deck 38, a base 40,and a plurality of columns 42. The columns 42 join the deck 38 to thebase 40. Preferably, the deck 38 and the base 40 are each formed fromthree composite plastic sheets. Alternatively, the deck 38 and base 40are constructed using twin sheets. The deck 38 and the base 40 snap fittogether and apart.

The plastic sheets are made from any suitable material, including, butnot limited to, commodity grade polyolefin materials, such aspolyethylene and polypropylene. Preferably, the suitable materialsinclude low cost, 100% recyclable materials having a multi-layer wallstructure that can withstand extreme handling conditions within amaterial handling environment.

Suitable multi-layer structures include a two layer structure having afire retardant layer and a support layer. The fire retardant layerincludes a polyolefin material and fire retardant fillers that providean average peak heat release rate of less than 500 kW/m² with a heatflux of 35 kW/m². Preferably, the peak heat release rate is between 500kW/m² and 300 kW/m² and, most preferably, less than 200 kW/m². Thesupport layer includes a polyolefin material with an effective amount oflow resistivity additives imparting high temperature strength.Preferably, the fire retardant layer includes low density polyethylenefor skid resistance, cold weather impact strength and excellentprocessibility and the thick layer of substrate supporting the thinlayer is comprised of high density polyethylene for high temperatureload strength, ease of processing and good physical properties.

The structure provides a sheet that does not break off during rugged usein the material handling environment, that does not burn, and that doesnot delaminate. The structure retains its mechanical properties longerunder elevated heat, fire, or other hazardous conditions to support aload. Optionally, the structure includes cross-linked polyethylene andpolypropylene to provide a uniform, robust, and undelaminatablestructure.

The use of commodity grade polyolefin materials reduces the materialcosts of the pallet. Preferably, the plastic sheets are formed from apolyolefin material having intumescent properties to prevent melting orignition upon exposure to flame. The intumescent properties are providedfrom intumescent additives that prevent the polyolefin base materialfrom dripping burning liquid and from spreading the flame. Theintumescent additives also react or decompose into a residual insulatingfoam-like structure that is resistant to burning.

The two layer structure includes comparably less fire retardantadditives than a single layer structure. The two layer structureprovides increased opportunities to reuse or to recycle the materials.Preferably, the two layer structure includes one or more markers. Themarkers are used to identify the base resin at the end of the palletlife cycle. The markers allow the resin supplier to recover the materialand ensure that the resin originated with the supplier. The markers alsoallow the resin to be reused because the supplier is able to confirm theidentity of the material.

Suitable materials also include relatively low cost materials thatutilize fewer expensive fire retardant additives. The GMA style pallethas 80 to 100 percent surface coverage because the pallet uses acombination of sheet products. Suitable combinations include a triplesheet structure that provides an uninterrupted layer upon the top andbottom surfaces of the pallet structure. The use of fewer fire retardantadditives also facilitates recycling of the base materials.

The pallet base materials typically include up to 30 wt % magnesiumhydroxide, 8 wt % alumina trihydrate, 8 wt % zinc borate, and 54 percentpolyolefin resin, so that the fire retardant additives do not exceed 46wt % of the base materials. The base materials provide a low peak heatrelease rate according to the test methods of ASTM E1354.

The specific gravity of high density polyethylene, such as Marlex® HXM50100 from ChevronPhillips Chemical Company LP of Woodlands, Tex., is0.95 g/cm³. The specific gravity of Mg(OH)₂, such as MagShield® S fromMartin Marietta of Raleigh, N.C., is 2.36 g/cm³. The specific gravity ofalumina trihydrate is 2.4 g/cm³. The specific gravity of zinc oxide,such as Firebrake® ZB from US Borax Inc. of Valencia, Calif., is 2.8g/cm³. The ratio of plastic to additives by volume in a pallet is closerto 6:1 and 8:1, despite the fact that the ratio of plastic to additivesis roughly 1:1 by weight.

The intumescent properties are imparted into the base material throughany suitable manufacturing process. Suitable manufacturing processesinclude blow molding, injection molding, rotational molding as well asany other method in which a first layer can be applied, laminated orotherwise affixed to a second layer to provide twin or triple layerpallet wall. The pallet assembly 36 is constructed through any suitabletechnique that forms a multi-layer pallet. Preferably, the palletassembly 36 is formed utilizing a sheet forming technique that producesa twin layer or triple layer pallet. The intumescent properties areimparted upon the outer exposed surfaces of the sheets through aco-extrusion process. The intumescent sheet construction prevents thepolyolefin from rapidly melting and dripping burning liquids. Theco-extrusion process provides a low cost, layered pallet structure.

The co-extrusion process provides the pallet assembly 30 with anintumescent outer layer covering a portion of or the entire outersurface of the assembly 36. The coverage should exceed 60% of the outersurface to prevent damaging of the objects within the pallets. Also, ahigher amount of surface coverage reduces the effective surface area andthe potential energy available for supporting a flame.

The use of an intumescent outer layer is necessary because polyolefinshave relatively low softening temperatures. Upon exposure to elevatedtemperatures, the softened polyolefin base material will lose itsstrength causing the pallet to collapse. The articles that are beingstored upon the collapsing pallet will spill off, which may result inadditional damage or injury to fire fighters.

The pallet assembly 36 includes a multi-layer wall structure that isamenable to the use of RF tracking devices within a supply chain. Theuse of a lower amount of hydrated, intercalated and conductive materialsin the two layer structure than in a single layer structure providesless interference in the two way transmission of radio frequencysignals, and in particular UHF signals preferred for near-field trackand trace systems. Preferably, the UHF signals utilize UHF frequencybands of around 860 MHz in Europe, 915 MHz in North America and 960 MHzin Asia.

The pallet assembly 36 is tracked through a network access portal suchas the Internet. The pallet assembly 36 includes RF transponder devicesthat are associated with the pallet assembly 36 to facilitate tracking.The transponder devices have unique identifiers for identifying thepallet assembly 36 within a network. The pallet assembly 36 ispositioned between a RF transponder and an interrogator (reader/writer)while it is within a supply chain. Preferably, the pallet includes lessthan 46 wt % of fire retardant additives to prevent interference with orblocking of the electromagnetic and the electrostatic coupling betweenthe transponder and the interrogator. The fire retardant additivesprovide an outer layer that has comparably higher RF resistivity thanthe inner layer.

The plastic pallet base material optionally includes an inner layerhaving reinforcing fibers, flakes, or fillers and an outer layer havingthe intumescent additives. The volume fraction of the fibers, flakes, orfillers does not affect the processability of the base material. Thefibers, flakes, or fillers also provide a high temperature load bearingstrength. Preferably, the ratio of the thickness of the first layer tothe second layer is between 4.25:6 or 1:2 to 1:10. Most preferably, theratio in the range 1:3 to 1:5. The poor processibility of the comparablythin first layer from a 4.24 inch extruder is overcome by the goodprocessibility of the thicker second layer from a 6 six extruder. Thecombination is RF transparent (less resistive).

The dimensions and style of a particular pallet assembly 36 are selectedfor a particular application. Suitable pallet styles include customizeddunnage for returnable shipping applications. Suitable dimensionsinclude 42×42 inches, 1200×800 mm, 1200×1000 mm, 1140×1140 mm and1100×1100 mm foot prints fall within the scope of the invention.Preferably, the pallet assembly 36 is a 48×40 inch rackable pallet or anesting pallet.

Referring now to FIG. 4, a nine-legged plastic pallet generallydesignated by the numeral 44 is shown. The plastic pallet 44 is anesting pallet that is used for distribution. The pallet 44 is notdesigned for racking (storage on warehouse racks). The pallet 44 ismolded from single, twin, triple and quadruple sheets. Preferably, thepallet 44 includes two or three sheets of molded composite plastics.

Referring now to FIGS. 5-6, a triple sheet pallet assembly 46 inaccordance with the present invention is shown. The pallet assembly 46includes a deck 48 and a base 50. The deck 48 is formed from threesheets 52, 54, 56. The base 50 is formed from three sheets 58, 60, 62.The sheets 54, 56 also extend downwardly to form a leg 64 having apocket 66. The sheets 60, 62 extend upwardly to form a leg 68 having apocket 70. The leg 64 has a deep draw ratio of 400%. Although the legsare shown decending from the deck to the base, the legs alternativelyextend from the base to the deck.

As shown in FIG. 6, the sheets 52, 56 are outer sheets. The sheets 52,56 have intumescent properties to prevent the polyolefin base materialfrom igniting or melting upon exposure to flame. The outer sheet 52includes an intumescent cap stock or layer 72 and a layer of basematerial 74. The outer sheet 56 includes an intumescent cap stock orlayer 76 and a layer of base material 78.

The intumescent properties of the intumescent layers 72, 76 also preventthe polyolefin base material from dripping burning liquid and fromspreading the flame. The intumescent additives in the cap stock 72, 76also react or decompose to convert the cap stock 72, 76 into a residualinsulating foam-like structure that is resistant to burning.

The intumescent layers 72, 76 have superior thermal insulatingproperties, so that the intumescent efficiency of the pallet surfacesprovides a thermal insulation effect. The intumescent materialscooperate with hollow areas of air space 80 provided within the triplesheet pallet construction to help preserve the integrity of the interiorstructural member of the pallet (i.e. sheet 54). The triple sheet deck48 provides superior support to a load upon exposure to heat or elevatedtemperatures, as compared to twin sheet or to injection molded palletsthat include the same amount of plastic.

The intumescent layers 72, 76 are made from any suitable intumescentmaterials. Suitable intumescent materials include reinforced orunreinforced materials. Suitable reinforced materials includereinforcing agents that are dispersed within a resin matrix and arecomposed of fibers and flakes including glass, carbon and ceramic fibersand flakes; fillers including titanium dioxide, mica, silica,wollastonite, calcium carbonate, sulfates; clays, such asmontmorillonite; beads; and nano-particles; or any combination thatsustain the stiffness of the plastic structure in elevated temperatureconditions.

The base material or structural layers 74, 78 are substantially thickerthan the intumescent layers 72, 76. The structural layers 74, 78 arerelatively flammable, so that the intumescent layers 72, 76 shield thestructural layers 74, 78 from fire damage. The intumescent layers 72, 76block oxygen from reaching the base material 74, 78. Preferably, theintumescent layers 72, 76 prevent the structural layers 74, 78 fromigniting and dripping flaming liquids that spread fire. Alternatively,the intumescent layers 72, 76 delay the spread of fire.

The intumescent layers 72, 76 also insulate the structural layers 74, 78from excessive heat, which allows the structural layers 74, 78 to retainload bearing strength for a longer period of time. The intumescentlayers 72, 76 also generate water, which reduces the intensity of fire(the peak heat release rate). The dual layered structure also allows theuse of a lower volume sprinkler system for extinguishing fires.

The intumescent layers 72, 76 and the structural layers 74, 78 includeadditives. Suitable additives organic nitrogenous gas emittingsubstances, inorganic water emitting substances, inorganic antioxidants,smoke suppressants, char forming fibers, char forming flakes, charforming fillers, strengthening fibers, strengthening flakes, andstrengthening fillers. The additives include conductive materials, suchas hydrated alumina, magnesium hydroxide, intercalated graphite,hydrated carbon, zinc borate and antimony oxide. The additives are fireresistant additives, strengthening additives, or fillers.

The fire resistant additives are concentrated in a thin outer layer toattenuate the resistivity of those materials, which results in less RFdistortion. A pallet having a fire resistant material distributed withina narrow layered portion of a given wall thickness will have a lowerinfluence on the carrier wave of a given frequency as compared to a fireresistant material dispersed throughout the entire given wall thickness.The lower the penetration depth of a resistive material the lower thedistortion. The present invention embodiment attenuates the electricresistivity of a pallet wall by concentrating the fire resistantcomponents that are also RF barrier materials into a thin section orexposed external layer of a thick wall.

The fire resistant or intumescent additives include both halogenated andnon-halogenated material components. Preferably, the intumescentadditives are non-halogenated material components because halogenspresent a hazard during the manufacture, use, and disposal of the palletmaterials. The use of non-halogenated components also protects firefighters. Halogens pose an extreme health hazard, and their use isenvironmentally destructive.

The halogen free intumescent composition includes a polyethylene orpolypropylene binder having a vapor generating or inorganic wateremitting substance. The vapor generating or inorganic water emittingsubstance cools down the fire and lowers the heat release rate. Suitableinorganic water emitting substances include hydrated magnesium, alumina,intercalated graphite, hydrated salts, clays, and nano-clays. Suitablesalts include salts that dissociate to form acids or bases upon heating,salts of strong acids and weak bases, salts of Lewis acids and bases,ammonium salts (such as ammonium sulfate or ammonium phosphate) andamine salts. Preferably, the inorganic water emitting substance is ahydrated salt, clay, or a nano-clay because fire retardant compositionsthat include hydrated magnesium, alumina, or intercalated graphite candistort RF signals.

Suitable non-halogenated materials also include an organic agent thatreleases a gas, such as a nitrogenous gas, that inhibits combustion. Thenitrogenous gas-generating ingredients reduce the heat during burningand also help foam the polymer matrix to provide an insulating charstructure. Suitable nitrogenous gases include urea, melamine, cyanurate,carbante, polyamide and the like.

Suitable non-halogenated fire retardant materials also includeintumescent materials that include certain ammonium salts, such asammonium polyphosphates having the chemical formula (NH₄PO₃)_(n). Theammonium polyphosphates are used in a lower concentration than watergenerating agents. The ammonium polyphosphates include a suitable carbonsupply, such as starch or pentaerythritol, to help in char formation,and melamine to assist in expanding the char. Additionally, the ammoniumpolyphosphates have superior properties with respect to lowering RFresistivity, as compared to hydrated metals.

Suitable non-halogenated compositions also include smoke suppressants,such as an antimony compound, a boron compound, a phosphorus compound,or any other suitable metal compounds.

Preferably, the halogen free intumescent formulation comprises, on thebasis of 100 parts by weight, 20-45 parts polyethylene or polypropylene,10-35 parts of an inorganic water vapor generating agent, 5-25 parts ofa nitrogenous gas generating agent, 1-5 parts of an antioxidant, and0-15 parts of a reinforcing agent. Optionally, the non-halogenatedcomposition includes reinforcing agents and heat stabilizingantioxidants. Suitable antioxidants include distearylthiodipropionate(DSTDP), hindered phenols and commercial products including Wingstay® L.

One or more of the constituent groups of the above described intumescentformulation can be omitted with successful results. However, otheringredients may be included provided that the material is halogen freeand is, preferably, transparent to RF signals.

The concentration of fire resistant additives in a thin outer layer alsoprovides a GMA style pallet that weighs 50 pounds or less. Fireretardant materials (for example metal hydroxides) are significantlyheavier than polyethylene and polypropylene (+/−2.5 times). Byconcentrating the comparably heavy additives in only one layer of a twolayer structure a lesser amount of additives are used to provide aneffective result. A smaller amount of heavier additives yields a lighterweight pallet, providing reduced transportation fuel costs and improvedergonomics. The concentration of fire resistant additives in the outerlayer also improves the processibility of non-halogenated materials.

The use of low density polyethylene or linear low density polyethyleneouter layer also provides skid resistance and improved processibility.Low density polyethylene and linear low density polyethylene have longermolecular chains, as compared to high density polyethylene or ultra highmolecular weight polyethylene. The longer molecular chains provide ahigher coefficient of friction, which provides higher skid resistancethan high density polyethylene or ultra high molecular weightpolyethylene. Preferably, the coefficient of static friction is higherthan 0.4 for the top surface of a pallet member and is higher than 0.15for the bottom surface of a pallet member.

In a two layer structure where the binder of the first fire resistantlayer and the substrate of the second structural layer cross link toprovide a uniform, undelaminatable structure, there will be lesstendency for the first layer to fry during fire or break off duringrobust use, thereby exposing an inside layer to potential fire damage.

The intumescent system has excellent thermal insulating properties.These properties provide protection for the interior structural sheet 54and layers 74, 78 against the heat that is generated by the hightemperature of the combustion flame. This protection prevents theinterior structural sheet 54 and layers 74, 78 from softening uponexposure to heat, so that the pallet will be able to maintain its loadcarrying properties.

Optionally, the pallet 44 includes cross members (not shown) that areinserted into the pallet 44 or positioned on recesses located in asurface on the pallet 44 to provide additional load bearing strength.The cross members (not shown) have intumescent properties to decreasethe pallet structure thermal conductivity. The cross members (not shown)help protect fire fighters working adjacent to the pallet loads when thepallet 44 is suspended in idle storage upon warehouse racks during afire. The cross members (not shown) also help reduce the damagingconsequences of a fire by maintaining the stored articles upon thepallets.

Referring now to FIG. 7, the member 28 shown in FIG. 2 is constructedout of an engineered composite. The member includes fire retardantadditives 82 that are dispersed uniformly throughout a matrix 84, as inan injection molded or structural foam molded polyethylene orpolypropylene resin product. A radio frequency signal, such as a UHFsignal 86, travels through the member 28 to exit as an attenuated UHFsignal 88. This is in marked contrast to the embodiments indicated inFIGS. 8-10, where the walls involve a plurality of layers, with threelayered examples provided.

Referring now to FIG. 8, the sheet 52 shown in FIG. 5 includes theintumescent layer 72 and the structural layer 74. The intumescent layer72 includes intumescent additives 90 to impart fire resistance and amatrix 92. The structural layer 74 includes reinforcing agents 94 and amatrix 96. A radio frequency signal, such as a UHF signal 98, travelsthrough the member 52 to exit as an attenuated UHF signal 100.

As shown in FIGS. 7-8, the attenuated UHF signal 88 is substantiallyweaker than the attenuated UHF signal 100 because the intumescent layer72 is substantially thinner than the structural layer 74. Theintumescent additives 90 are resistant to the UHF signal. The relativethickness of the structural layer 74 to the intumescent layer 72provides less attenuation of the UHF signal because the intumescentadditives 90 are concentrated in the intumescent layer 72. Couplingbetween the transponder and the interrogator is less distorted and proneto miscommunication in the embodiment shown in FIG. 8 compared to theembodiment shown in FIG. 7.

Referring now to FIG. 9, a sheet 102 is shown. The sheet 102 is asubstitute for the sheets 52, 56, 58, 62 shown in FIG. 5. The sheet 102includes two intumescent layers 104 and an interior layer 106. Theintumescent layers 104 are positioned at outer surfaces, so that theyare exposed to any potential source of fire or flames. The intumescentlayers 104 are essentially identical in composition to the intumescentlayer 72 shown in FIG. 8.

The interior layer 106 is essentially identical in composition to thestructural layer 74 shown in FIG. 8.

Preferably, the interior layer 106 includes a high density polyethyleneor ultra-high molecular weight polyethylene matrix 96.

The intumescent layers 104 are made from any suitable intumescentmaterials. Suitable intumescent materials include, but are not limitedto intumescent materials that include polyethylene and polypropylenematerials. Suitable polyethylene and polypropylene materials includeformulations that include regrind, recyclable byproducts of themanufacturing process, or a formulation comprising a polyethylene orpolypropylene resin grade that is different from the polyethylene andpolypropylene resin formulations contemplated in layer 106. Optionally,the layers 104 include fillers, flakes, fibers, or other similarmaterials.

Suitable intumescent materials also include linear low densitypolyethylene resins that provide improved hot tack adhesion for thebonding. Optionally, the sheet 102 includes additional layers thatinclude tie layers (not shown) to join the layers 104, 106 to oneanother. Such tie layers include, but are not limited to, a polyethylenelayer, a polypropylene layer, or an EVOH layer. U.S. Pat. No. 6,661,339describes such sheets having desirable barrier and performanceproperties and is hereby incorporated by reference.

The sheet 102 is produced by any suitable manufacturing process.Suitable processes include an ordinary co-extrusion process utilizing a4.25 inch extruder and a 6 inch extruder in tandem to provide a uniformsheet. The thicker substrate emanating from the six inch extruder cantherefore be modified with strengthening additives that are not used ina fire resistant formulation to provide a layered material combinationwith acceptable processability.

Referring now to FIG. 10, a sheet 108 is shown. The sheet 108 includesan intumescent layer 104, an interior layer 110, and a structural layer112. The interior layer 110 is essentially the same as the interiorlayer 106 shown in FIG. 9. However, the interior layer 110 includes areinforcing agent 114. The structural layer 112 includes reinforcingagents or fillers 116.

Referring now to FIGS. 11-15, additional embodiments of palletstructures 118, 120, 122, 124, 126 are shown. The pallet structure 118is a single walled pallet structure that is made from a single sheet 128of layered material. The pallet structure 120 is a double walled palletstructure. The pallet structure 120 is a triple walled pallet structurethat is similar to the pallet structure shown in U.S. Pat. No.6,749,418.

As shown in FIGS. 12-13, the sheets 130, 132 are formed into ribbedstructures to provide stiffness. The pallet structure 118 is a doublewalled pallet structure that is made from two sheets 130 of layeredmaterial. The pallet structure 120 is a triple walled pallet structurethat is made from three sheets 132 of layered material.

Referring now to FIGS. 14-15, the pallet structures 122, 124 aresandwich-type structures that include additional materials that providerigidity. The pallet structure 124 includes a pair of outer sheets 134that enclose a foam structure 136. The pallet structure 126 includes apair of outer sheets 138 that enclose separately molded inserts 140.

While the illustrative embodiment is a pallet, it should be understoodthe invention is practiced in the form of other material handlingdevices including bins, totes, containers, tanks and the like. In orderto obtain a plastic pallet that has high temperature load bearingstrength, fibers, flakes and fillers are added to the plastic material.In the preferred embodiment fibers, flakes and fillers are added in aneffective concentration that provides acceptable processability to thesubstrate layer. Acceptable processibility involves, in the presentpreferred embodiment of a thermoformed pallet, a PE and PP plastic sheetthat has at a minimum a 4:1 draw ratio capable of forming the deep legpockets of a pallet structure.

It should also be understood that the pallet structures can be made ofany plastic, wood, metal, cellulose material or combination thereof. Thepallet structures may be injection molded, blow molded, compressionmolded, differential pressure formed, stamped, die-cut, fabricated andassembled, welded, glued and bonded together. The pallets can take theform of GMA style 48×40 inch pallets, nine-legged nestable pallets,shipping trays, returnable dunnage, slaves and the like. Other productsfalling within the scope of the invention include IBCs, RPCs, ULDs, fueltanks and the like.

It should also be understood that replacing hydrated alumina Al(OH)₃with hydrated magnesium Mg(OH)₂ for plastic pallets provides materialshaving superior molding temperature resistance. A small measure ofAl(OH)₃ can however be used along with a large measure Mg(OH)₂ toinitiate an earlier response to the heat of fire.

It should also be understood that the use of hydrated carbon materialsto produce a fire resistant pallet is also contemplated. Upon heating tothe boiling point of water a hydrated carbon can be developed to expandto 80 times its original size through the exfoliation (enlargement) ofthe water molecules. The high heat of the thermoforming ovens used inpallet manufacturing, for example, would cause the sheet materialcontaining hydrated carbon to decompose during manufacture rather thanduring an intended fire related emergency.

According to the provisions of the patent statutes, I have explained theprinciple, preferred construction and mode of operation of my inventionand have illustrated and described what I now consider to represent itsbest embodiments. However, it should be understood that, within thescope of the appended claims, the invention may be practiced otherwisethan as specifically illustrated and described.

1. A method for producing a flame retardant-containing plastic shippingor storage container or one or more shaped parts thereof comprising thesteps: a) admixing a composition comprising (1) one or morethermosetting resins and one or more curing agents therefor, (2) a fullypre-polymerized uncrosslinked hydrocarbon polyolefin resin, andoptionally a fully pre-polymerized uncrosslinked functionalizedpolyolefin, and b) exposing said composition to curing conditions afterforming the composition into a shipping or storage container or one ormore shaped parts thereof, said shaped parts subsequently being securedtogether to form said shipping or storage container, wherein saidpolymeric composition comprises 1 to 49 parts by weight of said curablethermosetting resin, the parts by weight being based on the totalcomposition, and 51 to 99 parts by weight of a combination of at leastone of said fully prepolymerized uncrosslinked hydrocarbon polyolefinresin and said fully prepolymerized uncrosslinked functionalizedpolyolefin resin, the parts by weight being based on the totalcomposition, wherein said hydrocarbon polyolefin is present in the rangeof 25 to 99 parts by weight of the total composition and saidfunctionalized polyolefin is present in the range of 0 to 50 parts byweight of the total composition, and wherein said plastic containercomposition contains a flame retardant, said flame retardant beingselected from the group consisting of ammonium phosphates, compoundscontaining phosphorus-nitrogen bonds, and cyclic phosphates.
 2. A methodfor producing a flame retardant-containing plastic shipping or storagecontainer or one or more shaped parts thereof comprising the steps: a)admixing a composition comprising (1) one or more thermosetting resinsand one or more curing agents therefor, (2) a fully pre-polymerizeduncrosslinked hydrocarbon polyolefin resin, and optionally a fullypre-polymerized uncrosslinked functionalized polyolefin, and b) exposingsaid composition to curing conditions after forming the composition intoa shipping or storage container or one or more shaped parts thereof,said shaped parts subsequently being secured together to form saidplastic shipping or storage container, wherein said plastic containercomposition contains a flame retardant, said flame retardant beingselected from the group consisting of non-halogenated flame retardants,and wherein said plastic container further comprises one or more ofradio frequency identification (RFID)-tags.
 3. A method for producing aflame retardant-containing plastic pallet or one or more shaped partsthereof comprising the steps: a) admixing a composition comprising (1) 1to 49 parts by weight of one or more thermosetting resins and one ormore curing agents therefor, the parts by weight being based on thetotal composition, and (2) 51 to 99 parts by weight of a combination ofat least one of a fully pre-polymerized uncrosslinked hydrocarbonpolyolefin resin and optionally a fully pre-polymerized uncrosslinkedfunctionalized polyolefin resin, the parts by weight being based on thetotal composition, wherein said hydrocarbon polyolefin is present in therange of 25 to 99 parts by weight of the total composition and saidfunctionalized polyolefin is present in the range of 0 to 50 parts byweight of the total composition, and b) exposing said composition tocuring conditions after forming the composition into a plastic pallet orone or more shaped parts thereof, wherein said plastic pallet or one ormore shaped parts thereof contains a flame retardant, said flameretardant being selected from the group consisting of non-halogenatedflame retardants.